Strip castings of immiscible metals

ABSTRACT

The present invention discloses a method of strip casting an aluminum alloy from immiscible liquids that yields a highly uniform structure of fine second phase particles. The results of the present invention are achieved by using a known casting process to cast the alloy into a thin strip at high speeds. In the method of the present invention, the casting speed is preferably in the region of about 50-300 feet per minute (fpm) and the thickness of the strip preferably smaller than 0.08-0.25 inches. Under these conditions, favorable results are achieved when droplets of the immiscible liquid phase nucleate in the liquid ahead of the solidification front established in the casting process. The droplets of the immiscible phase are engulfed by the rapidly moving freeze front into the space between the Secondary Dendrite Arms (SDA).

RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No. 11/734,113, filed on Apr. 11, 2007. The entirety of this application is hereby incorporated herein by reference for the teachings therein.

FIELD OF THE INVENTION

This invention relates to the casting of metals and to a method of strip casting immiscible metals in particular.

BACKGROUND OF THE INVENTION

Aluminum based alloys containing Sn, Pb and Cd are commonly used in bearings found in internal combustion engines. The bearing function in these alloys is performed by the soft second phase particle of the alloying element which melts in the event of lubricant failure and prevents contact between the aluminum in the alloy and the steel protected by the bearing.

In the prior art, the soft second phase in these alloys separates during solidification and often appears in the form of non uniform distribution. In many cases the second phase forms at grain boundaries as a continuous layer, or the heavier component (Sn, Pb, Cd) settles to the bottom due to gravity segregation. Typically, heat treatment is required after cold rolling of the cast sheet to redistribute the soft phase. For Al—Sn alloys for example, this is done by an annealing treatment at 662° F. (350° C.) during which the soft phase melts and coagulates into a desired uniform distribution of unconnected particles. In a final processing step, the strip is bonded on a steel backing for use as bearings in engines.

Twin roll casting of Aluminum based bearing alloys yields better distribution of the second phase particles compared to conventional ingot casting. A drawback of twin roll casting, however, is that the method is slow, yields low productivity and creates a distribution of the soft phase(s) that is not completely desirable. Suitable results are also produced using a powder metallurgy process; however this method is expensive. There is a need, therefore, for a method that results in higher productivity and yields a uniform distribution of fine particles of the soft phase in the aluminum matrix.

SUMMARY OF THE INVENTION

The present invention discloses a method of strip casting an aluminum alloy from immiscible liquids that yields a highly uniform structure of fine second phase particles. The results of the present invention are achieved by using a known casting process to cast the alloy into a thin strip at high speeds. In the method of the present invention, the casting speed is preferably in the region of about 50-300 feet per minute (fpm) and the thickness of the strip preferably in the range of 0.08-0.25 inches. Under these conditions, favorable results are achieved when droplets of the immiscible liquid phase nucleate in the liquid ahead of the solidification front established in the casting process. The droplets of the immiscible phase are engulfed by the rapidly moving freeze front into the space between the Secondary Dendrite Arms (SDA).

As the SDA are small under rapid solidification conditions, (in the range of 2-10 μm) the droplets of the immiscible phase are uniformly distributed in the cast strip and are very fine.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a flow-chart describing the method of the present invention;

FIG. 2 is a schematic depicting an example of an apparatus that can perform the method of the present invention;

FIG. 3 is a perspective view detailing apparatus that can be operated in accordance with the present invention;

FIG. 4 is a cross-sectional view of the entry of molten metal to the apparatus illustrated in FIGS. 2 and 3; and

FIG. 5 is a photomicrograph of a transverse section of a strip produced in accordance with the present invention.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

The accompanying drawings and the description which follows set forth this invention in its preferred embodiments. It is contemplated, however, that persons generally familiar with casting processes will be able to apply the novel characteristics of the structures and methods illustrated and described herein in other contexts by modification of certain details. Accordingly, the drawings and description are not to be taken as restrictive on the scope of this invention, but are to be understood as broad and general teachings. When referring to any numerical range of values, such ranges are understood to include each and every number and/or fraction between the stated range minimum and maximum.

Finally, for purposes of the description hereinafter, the terms “upper”, “lower”, “right”, “left”, “vertical”, “horizontal”, “top”, “bottom”, and derivatives thereof shall relate to the invention, as it is oriented in the drawing figures.

The phrases “aluminum alloys”, are intended to mean alloys containing at least 50% by weight of the stated element and at least one modifier element. Suitable aluminum alloys include alloys of the Aluminum Association.

The method of the present invention is depicted schematically in the flow chart of FIG. 1. As depicted therein, in step 100 a molten metal comprising aluminum and at least one immiscible phase is introduced into a suitable casting apparatus. In step 102, the casting apparatus is operated at a casting speed greater than 50-300 fpm. In step 104, the thickness of the cast strip is maintained at 0.08-0.25 inch or smaller.

The method of the present invention is suitable for use with known casting methods such as those disclosed in U.S. Pat. Nos. 5,515,908 and 6,672,368 for example. These methods produce thin strips at high speeds resulting in productivity in the range 600 to 2000 lb/hr per inch of width cast.

An example of apparatus that can be employed in the practice of the present invention is illustrated in FIGS. 2, 3 and 4 of the drawings. The apparatus depicted therein is in accordance with that disclosed in Commonly owned U.S. Pat. No. 5,515,908 and is presented as only one example of apparatus that can be used to achieve the results of the method of the present invention.

The process will now be illustrated with respect to the apparatus depicted in FIG. 2, but is also applicable to the equipment depicted in FIGS. 3 and 4. As is depicted in FIG. 2, the apparatus includes a pair of endless belts 10 and 12 that act as casting molds carried by a pair of upper pulleys 14 and 16 and a pair of corresponding lower pulleys 18 and 20. Each pulley is mounted for rotation about an axis 21, 22, 24, and 26 respectively of FIG. 2. The pulleys are of a suitable heat resistant type, and either or both of the upper pulleys 14 and 16 is driven by a suitable motor means (not shown). The same is true for the lower pulleys 18 and 20. Each of the belts 10 and 12 is an endless belt, and is preferably formed of a metal which has low reactivity or is non-reactive with the metal being cast. Quite a number of suitable metal alloys may be employed as well known by those skilled in the art. Good results have been achieved using steel and copper alloy belts. Other metallic belts can also be used such as aluminum. It should be noted that in this embodiment of the invention casting molds are implemented as casting belts 10 and 12. However casting molds can comprise a single mold, one or more rolls or a set of blocks for example.

The pulleys are positioned, as illustrated in FIGS. 2 and 3, one above the other with a molding gap therebetween. The gap is dimensioned to correspond to the desired thickness of the metal strip being cast. Thus, the thickness of the metal strip being cast is determined by the dimensions of the nip between belts 10 and 12 passing over pulleys 14 and 18 along a line passing through the axis of pulleys 14 and 18 which is perpendicular to the casting belts 10 and 12. Molten metal to be cast is supplied to the molding zone through metal supply means 28 such as a tundish. The interior of tundish 28 corresponds in width to the width of the product to be cast, and can have a width up to the width of the narrower of the casting belts 10 and 12. The tundish 28 includes a metal supply delivery casting tip 30 to deliver a horizontal stream of molten metal to the molding zone between the belts 10 and 12.

Thus, the tip 30, as shown in FIG. 4, defines, along with the belts 10 and 12 immediately adjacent to tip 30, a molding zone into which the horizontal stream of molten metal flows. Thus, the stream of molten metal flowing substantially horizontally from the tip fills the molding zone between the curvature of each belt 10 and 12 to the nip of the pulleys 14 and 18. It begins to solidify and is substantially solidified by the point at which the cast strip reaches the nip of pulleys 14 and 18. Supplying the horizontally flowing stream of molten metal to the molding zone where it is in contact with a curved section of the belts 10 and 12 passing about pulleys 14 and 18 serves to limit distortion and thereby maintain better thermal contact between the molten metal and each of the belts as well as improving the quality of the top and bottom surfaces of the cast strip.

The casting apparatus shown in FIGS. 2, 3 and 4 includes a pair of cooling means 32 and 34 positioned opposite that portion of the endless belt in contact with the metal being cast in the molding gap between belts 10 and 12. The cooling means 32 and 34 thus serve to cool the belts 10 and 12 just after they pass over pulleys 16 and 20, respectively, and before they come into contact with the molten metal. As illustrated in FIGS. 2 and 3, the coolers 32 and 34 are positioned as shown on the return run of belts 10 and 12, respectively. The cooling means 32 and 34 can be conventional cooling means such as fluid cooling tips positioned to spray a cooling fluid directly on the inside and/or outside of belts 10 and 12 to cool the belts through their thicknesses.

Thus molten metal flows horizontally from the tundish through the casting tip 30 into the casting or molding zone defined between the belts 10 and 12 where the belts 10 and 12 are heated by heat transfer from the cast strip to the belts 10 and 12. The cast metal strip remains between and is conveyed by the casting belts 10 and 12 until each of them is turned past the centerline of pulleys 16 and 20. Thereafter, in the return loop, the cooling means 32 and 34 cool the belts 10 and 12, respectively, and remove therefrom substantially all of the heat transferred to the belts in the molding zone. The supply of molten metal from the tundish through the casting tip 30 is shown in greater detail in FIG. 4 of the drawings. As is shown in that figure, the casting tip 30 is formed of an upper wall 40 and a lower wall 42 defining a central opening 44 therebetween whose width may extend substantially over the width of the belts 10 and 12.

The distal ends of the walls 40 and 42 of the casting tip 30 are in substantial proximity to the surface of the casting belts 10 and 12, respectively, and define with the belts 10 and 12 a casting cavity or molding zone 46 into which the molten metal flows through the central opening 44. As the molten metal in the casting cavity 46 flows between the belts 10 and 12, it transfers its heat to the belts 10 and 12, simultaneously cooling the molten metal to form a solid strip 50 maintained between casting belts 10 and 12. Sufficient setback (defined as the distance between first contact 47 of the molten metal 46 and the nip 48 defined as the closet approach of the entry pulleys 14 and 18) is provided to allow substantially complete solidification prior to the nip 48.

To produce the results yielded by the method of the present invention utilizing the apparatus described in FIGS. 2-4, a molten aluminum based alloy comprising a phase that is immiscible in the liquid state is introduced via tundish 28 of FIG. 3 through casting tip 30 into the casting zone defined between belts 10 and 12. Preferably, the dimensions of the nip between belts 10 and 12 passing over pulleys 14 and 18 should be in the range of 0.08 to 0.25 inches , and the casting speed is 50 -300 fpm. Under these conditions, droplets of the immiscible liquid phase nucleate ahead of the solidification front and are engulfed by the rapidly moving freeze front into the space between the SDA spaces. Thus, the resulting cast strip contains a uniform distribution of the droplets of the immiscible phase.

Turning now to FIG. 5 a photomicrograph of a section of a Al-6Sn strip 400 produced in accordance with the present invention is shown. The strip shows a highly uniform distribution of fine Sn particles 401 which are 3 μm or smaller. This result is several times smaller than particles that would result from material made from an ingot or by roll casting which are typically 40-400 μm in size. Moreover, the strip produced by the present invention requires no heat treatment for re-distribution of the soft phase and is ideal for providing the required lubricating properties for use in bearings for example. If so desired the strip can be used in as-cast form without being subject to additional fabrication such as rolling for example.

Having described the presently preferred embodiments, it is to be understood that the invention may be otherwise embodied within the scope of the appended claims. 

What is claimed is:
 1. A product comprising: a cast aluminum alloy product comprising: an aluminum alloy; and at least 0.1 weight percent alloying addition, wherein the alloying addition is substantially immiscible with molten aluminum, wherein particles of the substantially immiscible alloying addition are uniformly distributed throughout the cast aluminum alloy product, and wherein the particles are deposited between secondary dendrite arms of the cast aluminum alloy product.
 2. The product according to claim 1, wherein the particles are less than three microns in size.
 3. The product according to claim 1, wherein the alloying addition comprises at least one of Sn, Pb, Bi, Cd, and Sb.
 4. The product according to claim 1, wherein the alloying addition comprises at least 0.1 weight % Sn.
 5. The product according to claim 1, wherein the alloying addition comprises at least 0.1 weight % Pb.
 6. The product according to claim 1, wherein the alloying addition comprises at least 0.1 weight % Bi.
 7. The product according to claim 1, wherein the alloying addition comprises at least 0.1 weight % Cd.
 8. The product according to claim 1, wherein the alloying addition comprises at least 0.1 weight % Sb.
 9. A method of casting metals comprising: providing a molten aluminum alloy to a casting apparatus, the molten aluminum alloy comprising at least about 0.1 weight percent alloying addition, wherein the alloying addition is substantially immiscible with molten aluminum, the casting apparatus having a first casting surface, a second casting surface, and a nip formed between the first and second casting surface; advancing the aluminum alloy, wherein a point of complete solidification of the aluminum alloy is formed at the nip, wherein the aluminum alloy is advanced through the nip, by rotation of the first casting surface and by rotation of the second casting surface, wherein fine droplets of the immiscible alloying addition deposit between secondary dendrite arms of the aluminum alloy, wherein the fine droplets are less than three microns in size, and wherein the fine droplets of the immiscible alloying addition are uniformly distributed throughout the alloy.
 10. The method according to claim 9, wherein the nip comprises a thickness ranging from 0.08 inches to 0.25 inches.
 11. The method according to claim 9, wherein the alloying addition comprises at least one of Sn, Pb, Bi, Cd, and Sb.
 12. The method according to claim 9, wherein the alloying addition comprises at least 0.1 weight % Sn.
 13. The method according to claim 9, wherein the alloying addition comprises at least 0.1 weight % Pb.
 14. The method according to claim 9, wherein the alloying addition comprises at least 0.1 weight % Bi.
 15. The method according to claim 9, wherein the alloying addition comprises at least 0.1 weight % Cd.
 16. The method according to claim 9, wherein the alloying addition comprises at least 0.1 weight % Sb. 